Seal plate with insulation displacement connection

ABSTRACT

An end effector assembly having first and second jaw members is provided where one or both of the jaw members is moveable relative to the other between a spaced-apart position and an approximated position for grasping tissue therebetween. One (or both) of the jaw members includes an inwardly-facing surface having a slot defined therein and a wire having an insulative coating. A seal plate has at least one protrusion that is configured to be disposed in the slot. The at least one protrusion of the seal plate is configured to displace the insulative coating from the wire thereby forming an electrical connection therewith when the at least one protrusion is disposed in the slot.

CROSS REFERENCE TO RELATED APPLICATION

The present application is a continuation of U.S. patent applicationSer. No. 13/234,357, filed on Sep. 16, 2011, the entire contents ofwhich are incorporated herein by reference.

BACKGROUND

The present disclosure relates to surgical instruments and, moreparticularly, to a surgical instrument with a seal plate that snaps intoa jaw member and creates an insulation displacement connection betweenthe seal plate and a RF wire.

TECHNICAL FIELD

Electrosurgical instruments, e.g., electrosurgical forceps, utilize bothmechanical clamping action and electrical energy to affect hemostasis byheating tissue to coagulate and/or cauterize tissue. Certain surgicalprocedures require more than simply cauterizing tissue and rely on theunique combination of clamping pressure, precise electrosurgical energycontrol and gap distance (i.e., distance between opposing jaw memberswhen closed about tissue) to “seal” tissue.

As can be appreciated, in order to create an effective tissue seal,different considerations are taken into account depending on thecharacteristics, e.g., composition, structure and/or function, of thetissue to be sealed.

SUMMARY

As used herein, the term “distal” refers to the portion that is beingdescribed which is further from a user, while the term “proximal” refersto the portion that is being described which is closer to a user.

In accordance with one aspect of the present disclosure, an end effectorassembly having first and second jaw members is provided. One (or both)of the jaw members is moveable relative to the other between aspaced-apart position and an approximated position for grasping tissuetherebetween. One (or both) of the jaw members includes aninwardly-facing surface having a slot defined therein and a first wirehaving an insulative coating. One (or both) of the jaw members furtherincludes a seal plate that has at least one protrusion that isconfigured to displace the insulative coating from the wire therebyforming an electrical connection therewith when the at least oneprotrusion is disposed in the slot.

The protrusion of the seal plate may further include a sharpened edgefor facilitating removal of the insulative coating. The sharpened edgemay be v-shaped, u-shaped, substantially flat shaped, rectangularshaped, or pentagon shaped. The slot may have a general polynomialshape.

In a further aspect of the invention, each of the jaw members includesan inwardly-facing surface having a slot defined therein and a wirehaving an insulative coating. Each jaw member is configured to receive aseal plate having at least one protrusion wherein the slot is configuredto receive the protrusion. The protrusions displace the insulativecoating of each wire in each of the jaw members when the protrusions ofthe seal plates are disposed in the slots of the respective jaw members.The wire of one jaw member and the wire of the second jaw member mayhave opposite polarities.

According to another aspect of the present disclosure, a method ofmanufacturing an end effector assembly includes the step of providingfirst and second jaw members. At least one of the jaw members includingan inwardly-facing surface having a slot defined therein and a wirehaving an insulative coating. The method further includes the step ofdisposing at least one protrusion of a seal plate within the slot tosecure the seal plate atop the jaw member thereby causing the protrusionto displace the insulative coating from the wire to form an electricalconnection between the seal plate and the wire.

The protrusion of the seal plate further may include a sharpened edgefor facilitating removal of the insulative coating. The sharpened edgemay be v-shaped, u-shaped, substantially flat shaped, rectangularshaped, or pentagon shaped. The slot may have a general polynomialshape.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present disclosure are described in detail withreference to the drawing figures wherein like reference numeralsidentify similar or identical elements and wherein:

FIG. 1 is a front, perspective view of an endoscopic surgical instrumentconfigured for use in accordance with the present disclosure;

FIG. 2 is a front, perspective view of an open surgical instrumentconfigured for use in accordance with the present disclosure;

FIG. 3 is a front, perspective view of one embodiment of an end effectorassembly configured for use with the surgical instrument of FIG. 1;

FIGS. 4A-4B are side views of one of the jaw members of the end effectorassembly of FIG. 3;

FIG. 5A is a cross-section view along axis B-B of the jaw member of FIG.4A;

FIGS. 5B-5D are alternative embodiments of the first end shown in FIG.5A; and

FIG. 6 is a flow diagram of a process for connecting a seal plate, a RFwire, and a jaw member in accordance with an embodiment of the presentdisclosure.

DETAILED DESCRIPTION

As used herein, the term “distal” refers to the portion that is beingdescribed which is further from a user, while the term “proximal” refersto the portion that is being described which is closer to a user.

Referring now to FIGS. 1 and 2, FIG. 1 depicts a forceps 10 for use inconnection with endoscopic surgical procedures and FIG. 2 depicts anopen forceps 10′ contemplated for use in connection with traditionalopen surgical procedures. For the purposes herein, either an endoscopicinstrument, e.g., forceps 10, or an open instrument, e.g., forceps 10′,may be utilized in accordance with the present disclosure. Obviously,different electrical and mechanical connections and considerations applyto each particular type of instrument; however, the novel aspects withrespect to the end effector assembly and its operating characteristicsremain generally consistent with respect to both the open and endoscopicconfigurations.

Turning now to FIG. 1, an endoscopic forceps 10 is provided defining alongitudinal axis “X-X” and including a housing 20, a handle assembly30, a rotating assembly 70, a trigger assembly 80, an actuator 90, andan end effector assembly 100. Forceps 10 further includes a shaft 12having a distal end 14 configured to mechanically engage end effectorassembly 100 and a proximal end 16 that mechanically engages housing 20.Housing 20 contains the internal working components of the forceps 10which are not described herein but which may be found, for example, incommonly-owned U.S. Pat. No. 7,156,846.

End effector assembly 100 is shown attached at a distal end 14 of shaft12 and includes a pair of opposing jaw members 110 and 120. Jaw members110, 120 are moveable between a spaced-apart position and anapproximated position for grasping tissue therebetween. End effectorassembly 100 is designed as a unilateral assembly, i.e., where jawmember 120 is fixed relative to shaft 12 and jaw member 110 is moveableabout pivot 103 relative to shaft 12 and fixed jaw member 120. However,end effector assembly 100 may alternatively be configured as a bilateralassembly, i.e., where both jaw member 110 and jaw member 120 aremoveable about a pivot 103 relative to one another and to shaft 12.

With continued reference to FIG. 1, forceps 10 also includeselectrosurgical cable 610 that connects forceps 10 to a generator (notshown) or other suitable power source, although forceps 10 mayalternatively be configured as a battery-powered instrument. Cable 610includes a wire (or wires) (not explicitly shown) extending therethroughthat has sufficient length to extend through shaft 12 in order toprovide electrical energy to at least one of the jaw members 110 and 120of end effector assembly 100. Trigger 82 of trigger assembly 80 may beselectively depressed to advance a knife (not shown) between jaw members110, 120 to cut tissue grasped therebetween. Actuator 90, on the otherhand, is selectively activatable to supply electrosurgical energy to one(or both) of jaw members 110, 120, as will be described in greaterdetail below.

With continued reference to FIG. 1, handle assembly 30 includes fixedhandle 50 and a moveable handle 40. Fixed handle 50 is integrallyassociated with housing 20 and handle 40 is moveable relative to fixedhandle 50. Rotating assembly 70 is rotatable in either direction about alongitudinal axis “X-X” to rotate end effector 100 about longitudinalaxis “X-X.” Moveable handle 40 of handle assembly 30 is ultimatelyconnected to a drive assembly (not shown) that, together, mechanicallycooperate to impart movement of jaw members 110 and 120 between thespaced-apart position and the approximated position to grasp tissuedisposed between jaw members 110, 120. As shown in FIG. 1, moveablehandle 40 is initially spaced-apart from fixed handle 50 and,correspondingly, jaw members 110, 120 are in the spaced-apart position.Moveable handle 40 is depressible from this initial position to adepressed position corresponding to the approximated position of jawmembers 110, 120.

Referring now to FIG. 2, an open forceps 10′ is shown including twoelongated shafts 12 a and 12 b, each having a proximal end 16 a and 16b, and a distal end 14 a and 14 b, respectively. Similar to forceps 10(FIG. 1), forceps 10′ is configured for use with end effector assembly100. More specifically, end effector assembly 100 is attached to distalends 14 a and 14 b of shafts 12 a and 12 b, respectively. As mentionedabove, end effector assembly 100 includes a pair of opposing jaw members110 and 120 that are pivotably connected about a pivot 103. Each shaft12 a and 12 b includes a handle 17 a and 17 b disposed at the proximalend 16 a and 16 b thereof. Each handle 17 a and 17 b defines a fingerhole 18 a and 18 b therethrough for receiving a finger of the user. Ascan be appreciated, finger holes 18 a and 18 b facilitate movement ofthe shafts 12 a and 12 b relative to one another that, in turn, pivotsjaw members 110 and 120 from an open position, wherein the jaw members110 and 120 are disposed in spaced-apart relation relative to oneanother, to a closed position, wherein the jaw members 110 and 120cooperate to grasp tissue therebetween.

A ratchet 30′ may be included for selectively locking the jaw members110 and 120 relative to one another at various positions duringpivoting. Ratchet 30′ may include graduations or other visual markingsthat enable the user to easily and quickly ascertain and control theamount of closure force desired between the jaw members 110 and 120.

With continued reference to FIG. 2, one of the shafts, e.g., shaft 12 b,includes a proximal shaft connector 19 which is designed to connect theforceps 10′ to a source of electrosurgical energy such as anelectrosurgical generator (not shown). Proximal shaft connector 19secures an electrosurgical cable 610′ to forceps 10′ such that the usermay selectively apply electrosurgical energy to jaw member 110 and/orjaw member 120 of end effector assembly 100.

Referring now to FIGS. 3-5, one embodiment of an end effector assemblyprovided in accordance with the present disclosure is shown generallyidentified by reference numeral 200. End effector assembly 200 may beadapted for use with either forceps 10 (FIG. 1), forceps 10′ (FIG. 2),or any other suitable surgical instrument (not shown). However, asshown, end effector assembly 200 is disposed at distal end 14 of shaft12 of forceps 10 (FIG. 1). Similar to end effector assembly 100, endeffector assembly 200 includes first and second jaw members 210, 220,respectively, pivotably coupled to one another about pivot 203 andmovable between a spaced-apart position and an approximated position forgrasping tissue therebetween. As shown, end effector assembly 200defines a unilateral configuration wherein jaw member 220 is fixed andjaw member 210 is movable relative to jaw member 220 between thespaced-apart and approximated positions. However, this configuration maybe reversed, or end effector assembly 200 may be configured as abilateral configuration, e.g., where both jaw members 210, 220 aremoveable.

With continued reference to FIGS. 3-5, each jaw member 210, 220 includesan outer jaw housing 212, 222 and an inwardly facing surface 214, 224,respectively. Surfaces 214, 224 of jaw members 210, 220, respectively,are formed at least partially from an electrically-insulative material.An electrically-conductive tissue sealing plate 300 is snapped orotherwise securely engaged into each surface 214, 224 such that tissuesealing plates 300 oppose one another. The tissue sealing plates 300 ofjaw members 210, 220 are substantially similar and, thus, the tissuesealing plate of jaw member 210 is not shown or described herein toavoid unnecessary repetition.

FIG. 4A shows a side view of jaw member 220 along axis A-A prior tosnapping the sealing plate 300 onto surface 224. Surface 224 may includefirst and second slots 242, 244 that are configured to receiveprotrusions 305, 310 protruding from sealing plate 300. Slots 242, 244may be of any shape or size to accommodate differently shaped sealingplates 300.

Sealing plate 300 includes at least one protrusion, for example, firstprotrusion 305, that mates with at least a first slot 242 within surface224. As shown in FIGS. 4A and 4B, the sealing plate 300 includes a firstprotrusion 305 and a second protrusion 310 that snap into slots 242,244, respectively, within surface 224. The use of at least twoprotrusions 305, 310, and two slots 242, 244 reduces longitudinal orlateral movement of the sealing plate 300. In some embodiments, only oneprotrusion may be utilized to reduce longitudinal or lateral movement ofthe sealing plate 300. In other embodiments, three or more protrusionsmay be utilized to reduce longitudinal or lateral movement of thesealing plate 300.

A RF wire 250 is either run through jaw member 220 or connects to a wire(not shown) within shaft 12. The RF wire 250 includes an insulativecoating 260 surrounding a conductor wire 255 (See FIG. 5). The RF wire250 is ultimately connected to a generator (not shown) via eitherforceps 10 or 10′.

When the first protrusion 305 of the sealing plate 300 snaps into slot242, the insulative coating 260 is removed from the RF wire 250 and aninsulation displacement connection (IDC) is made between the RF wire 250and the first protrusion 305 of the seal plate 300. The use of the IDCfacilitates assembly of the sealing plate 300 atop the respective jawmember, e.g., jaw member 220, and eliminates soldering or crimping atassembly.

FIG. 4B shows the seal plate 300 snapped onto surface 224. The sealingplate 300 may be snapped onto surface 224 prior to connecting jaw member220 to shaft 12. Alternatively, the sealing plate 300 may be connectedto surface 224 after the jaw member 220 is connected to shaft 12.Alternatively, jaw member 220 may be permanently attached to shaft 12.

FIG. 5A shows a cross-section of jaw member 220 along the axis B-B ofFIG. 4A. Surface 224 is shown in cross hatch and includes slot 242. Slot242 is generally a polynomial shape and is shown with pentagon typeshape; however, the shape may be u-shaped, rectangular shaped, v-shaped,or other suitable shape. The first protrusion 305 of the sealing plate300 includes a sharpened edge 315 for facilitating removal of theinsulative coating 260. The sharpened edge 315 is shown with a v-shapedcutting edge; however, the sharpened cutting edge may be shaped with arectangular cutting edge 330 (See FIG. 5D), u-shaped cutting edge 320(See FIG. 5B), flat cutting edge 325 (See FIG. 5C), pointed, or othersuitable shape to assist in removing the insulative coating 260 from theRF wire. As the RF wire 250 is pushed into slot 242 by the firstprotrusion 305 of sealing plate 300, a section of the insulative coating260 is removed from RF wire 250 to create the IDC between the conductorwire 255 and the seal plate 300. The IDC allows an electrical signal tobe sent from the generator (not shown) to the seal plate 300 via RF wire250.

FIG. 6 is a flow diagram of a process 600 for connecting a seal plate300, a RF wire 250, and a jaw member 220 according to an embodiment ofthe invention. The process 600 starts at step 605, when a jaw member 220is connected to a forceps 10 or 10′ at step 610. Next at step 620, theRF wire 250 is threaded into jaw member 220. The RF wire 250 may be apart of jaw member 220 and attached to a wire (not shown) within theshaft 12 or the wire from shaft 12 may be threaded through jaw member220 as jaw member 220 is attached to shaft 12. Alternatively, the jawmember 220 may be permanently attached to the forceps 10 or 10′ with theRF wire 250 already part of the forceps 10, 10′ and jaw member 220 or atube may conduct the energy through the shaft and include a wire-likeelement at a distal end thereof that ultimately connects to the IDC.

At step 630, the seal plate 300 is snapped into at least one slot 242,244 within surface 224. As the seal plate 300 is snapped into place, thesharpened edge 315 of first protrusion 305 removes the insulativecoating 260 is from RF wire 250 creating an insulation displacementconnection (IDC) between RF wire 250 and seal plate 300 to allow anelectrical signal to pass from RF wire 250 to seal plate 300. Next, atstep 640, a user grasps tissue between the jaw members 210, 220. Energyis then supplied from a generator (not shown) through the RF wire 250 toseal plate 300 at step 650. The RF wire 250 may be connected to thegenerator before or after snapping seal plate 300 onto surface 224. Theprocess 600 then ends at step 665 after conducting energy between jawmembers 210, 220 to create a tissue seal at step 660.

From the foregoing and with reference to the various figure drawings,those skilled in the art will appreciate that certain modifications canalso be made to the present disclosure without departing from the scopeof the same. While several embodiments of the disclosure have been shownin the drawings, it is not intended that the disclosure be limitedthereto, as it is intended that the disclosure be as broad in scope asthe art will allow and that the specification be read likewise.Therefore, the above description should not be construed as limiting,but merely as examples of particular embodiments. Those skilled in theart will envision other modifications within the scope and spirit of theclaims appended hereto.

1-10. (canceled)
 11. A jaw member for an end effector assembly of anelectrosurgical instrument, the jaw member comprising: aninwardly-facing surface defining a slot; a wire having an insulativecoating; and a seal plate having a protrusion configured to displace theinsulative coating from the wire upon engagement therewith to form anelectrical connection between the wire and the seal plate when theprotrusion engages the slot.
 12. The jaw member according to claim 11,wherein the protrusion includes a sharpened edge that facilitatesdisplacement of the insulative coating.
 13. The jaw member according toclaim 12, wherein the sharpened edge is v-shaped, u-shaped, flat,rectangular, or pentagonal.
 14. The jaw member according to claim 11,wherein the wire is disposed within the slot.
 15. The jaw memberaccording to claim 11, wherein the inwardly-facing surface defines asecond slot and the seal plate includes a second protrusion, the secondprotrusion configured to displace the insulative coating from the wireupon engagement therewith to form an electrical connection between thewire and the seal plate when the second protrusion engages the secondslot.
 16. A method of manufacturing a jaw member, the method comprising:threading a wire into an inwardly-facing surface of a jaw member; andengaging a seal plate having a protrusion with the inwardly facingsurface such that the protrusion displaces an insulative coating fromthe wire to form an electrical connection between the seal plate and thewire.
 17. The method according to claim 16, wherein threading the wireinto the inwardly-facing surface includes threading the wire into a slotdefined within the inwardly-facing surface.
 18. The method according toclaim 16, wherein engaging the seal plate having the protrusion with theinwardly facing surface includes utilizing an edge of the inwardlyfacing surface to displace the insulative coating from the wire.
 19. Themethod according to claim 16, wherein engaging the seal plate having theprotrusion with the inwardly facing surface includes snapping the sealplate to the inwardly facing surface.
 20. The method according to claim16, wherein engaging the seal plate having the protrusion with theinwardly-facing surface includes disposing the protrusion within a slotdefined in the inwardly-facing surface.
 21. A method of manufacturing ajaw member, the method comprising: threading a wire into aninwardly-facing surface of a jaw member; and disposing a protrusion of aseal plate within a slot defined in the inwardly-facing surface tosecure the seal plate to the jaw member such that the protrusiondisplaces an insulative coating from the wire to form an electricalconnection between the seal plate and the wire.
 22. The method accordingto claim 21, wherein threading the wire into the inwardly-facing surfaceincludes threading the wire into the slot.
 23. The method according toclaim 21, wherein disposing the protrusion of the seal plate within theslot includes utilizing a sharpened edge to displace the insulativecoating from the wire.
 24. The method according to claim 21, whereindisposing the protrusion of the seal plate within the slot includessnapping the seal plate to the inwardly-facing surface.